U.S. patent application number 13/368651 was filed with the patent office on 2013-08-08 for solar panel clamp.
This patent application is currently assigned to Preformed Line Products. The applicant listed for this patent is Darius J. Kaunas, John B. Markiewicz. Invention is credited to Darius J. Kaunas, John B. Markiewicz.
Application Number | 20130200245 13/368651 |
Document ID | / |
Family ID | 48902079 |
Filed Date | 2013-08-08 |
United States Patent
Application |
20130200245 |
Kind Code |
A1 |
Markiewicz; John B. ; et
al. |
August 8, 2013 |
SOLAR PANEL CLAMP
Abstract
Among other things, one or more clamping apparatuses for
securing a photovoltaic module to a rail are described. The
clamping apparatus comprises, among other things, a spacer that is
configured to cause a space of a specified distance to be created
between a clamp of the clamping apparatus and a rail to which the
photovoltaic module is secured. In this way, the clamping apparatus
may be attached to the rail prior to the module being positioned
relative to the rail. Moreover, one or more methods are described
for preassembling a rail that comprises clamping apparatuses and/or
for preassembling a clamping apparatus. Such preassembly of the
clamping apparatus may reduce installation time and reduce total
cost associated with photovoltaic arrays.
Inventors: |
Markiewicz; John B.;
(Mentor, OH) ; Kaunas; Darius J.; (Medina,
OH) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Markiewicz; John B.
Kaunas; Darius J. |
Mentor
Medina |
OH
OH |
US
US |
|
|
Assignee: |
Preformed Line Products
Mayfield Village
OH
|
Family ID: |
48902079 |
Appl. No.: |
13/368651 |
Filed: |
February 8, 2012 |
Current U.S.
Class: |
248/500 ;
29/525.08; 29/525.11 |
Current CPC
Class: |
F16B 7/187 20130101;
Y10T 29/49963 20150115; Y02E 10/47 20130101; F24S 2025/807
20180501; F24S 25/33 20180501; F24S 25/636 20180501; Y10T 29/49959
20150115 |
Class at
Publication: |
248/500 ;
29/525.11; 29/525.08 |
International
Class: |
F16B 35/00 20060101
F16B035/00; B23P 11/00 20060101 B23P011/00; B23P 17/00 20060101
B23P017/00 |
Claims
1. A clamping apparatus configured to secure one or more
photovoltaic modules to a rail, comprising: a bolt comprising a
shaft, the bolt comprising a first end and a second end; a clamp
configured to secure the one or more photovoltaic modules to the
rail, the clamp configured to be selectively coupled to the shaft;
and a spacer configured to position the clamp a specified distance
from the first end of the bolt.
2. The apparatus of claim 1, the first end of the bolt comprising a
t-shaped head configured to be inserted into a channel of the
rail.
3. The apparatus of claim 1, the shaft comprising a non-cylindrical
portion and the clamp comprising a non-cylindrically shaped
aperture, the aperture substantially similar in shape to the
non-cylindrical portion of the shaft.
4. The apparatus of claim 3, the clamp comprising one or more tabs,
the one or more tabs and the non-cylindrically shaped aperture
facilitating an alignment of the first end of the bolt within a
channel of the rail, such that rotation of the bolt relative to the
channel is mitigated once the clamp secures the one or more
photovoltaic modules.
5. The apparatus claim 1, the clamp comprising one or more tabs
configured to be at least partially inserted between two or more
photovoltaic modules.
6. The apparatus of claim 1, comprising a nut configured to be
selectively coupled to the shaft via the second end and to secure
the clamp and the spacer to the bolt.
7. The apparatus of claim 6, the clamp, the spacer, and the nut
selectively coupled to the shaft to preassemble the clamping
apparatus prior to attachment of the clamping apparatus to the
rail.
8. The apparatus of claim 1, the spacer comprised of a compressible
material.
9. The apparatus of claim 1, the spacer comprised of a spring.
10. The apparatus of claim 1, the spacer comprised of
polystyrene.
11. The apparatus of claim 1, the spacer comprised of a
compressible metal structure.
12. The apparatus of claim 1, comprising a grounding clip
configured to ground the clamping apparatus.
13. The apparatus of claim 12, the grounding clip comprising a
washer.
14. A method, comprising: preassembling a rail configured to secure
one or more photovoltaic modules, comprising: coupling a clamping
apparatus to the rail, the clamping apparatus configured to secure
the one or more photovoltaic modules to the preassembled rail, the
clamping apparatus comprising a bolt, a clamp, and a spacer, the
spacer configured to position the clamp a specified distance from
an edge of the rail to which the bolt is inserted.
15. The method of claim 14, comprising shipping the preassembled
rail for assembly with the one or more photovoltaic modules.
16. The method of claim 14, comprising inserting the one or more
photovoltaic modules into a space, at least partially defined by
the spacer, between the edge of the rail and the clamp.
17. The method of claim 16, comprising securing the one or more
photovoltaic modules to the rail by compressing the spacer such
that the space between the edge of the rail and the clamp is
reduced.
18. The method of claim 14, coupling the clamping apparatus to the
rail, comprising: inserting a first end of a bolt into a channel of
the rail, where the spacer facilitates maintaining an orientation
of the bolt relative to the rail.
19. The method of claim 18, coupling the clamping apparatus to the
rail, comprising: placing the spacer onto the bolt via an aperture
of the spacer, the spacer positioned between the rail and a second
end of the bolt; and placing the clamp onto the bolt via an
aperture of the clamp, the spacer positioned between the rail and
the clamp.
20. The method of claim 19, the bolt comprising a shaft having a
non-cylindrical portion and the clamp configured to be inserted
onto the bolt via a non-cylindrical aperture of the clamp that
substantially corresponds to the non-cylindrical portion of the
shaft.
21. The method of claim 14, comprising, prior to coupling the
clamping apparatus to the rail, assembling the coupling apparatus,
assembling the coupling apparatus comprising: inserting a shaft of
the bolt through a corresponding aperture of the spacer; and
inserting a non-cylindrical portion of the shaft through a
non-cylindrical aperture of the clamp, such that rotation of the
clamp relative to the bolt is mitigated.
22. A clamping apparatus configured to secure one or more
photovoltaic modules to a rail, comprising: a bolt comprising a
t-shaped head and a shaft; a clamp configured to secure the one or
more photovoltaic modules to the rail, the clamp configured to be
selectively coupled to the shaft; and a compressible spacer
configured to be selectively coupled to the shaft and to position
the clamp a specified distance from the head of the bolt.
23. The apparatus of claim 22, the shaft comprising a
non-cylindrical portion and the clamp comprising a non-cylindrical
aperture through which the non-cylindrical portion of the shaft is
passed, the non-cylindrical aperture having a shape that
substantially corresponds to a shape of the non-cylindrical portion
of the shaft.
24. The apparatus of claim 22, the t-shaped head comprising a
rounded corner and three substantially square corners such that the
bolt can be rotated in merely one direction relative to the rail
when the t-shaped head of the bolt is inserted into a channel of
the rail.
25. A method for securing a photovoltaic module to a rail,
comprising: placing the photovoltaic module proximate the rail;
inserting one end of a preassembled clamping apparatus into a
channel of the rail, the preassembled clamping apparatus comprising
at least a bolt, a clamp, and a spacer, the spacer configured to
position the clamp a specified distance from an edge of the rail;
and compressing the spacer to reduce the distance between the clamp
and the edge of the rail and to secure the photovoltaic module to
the rail.
26. The method of claim 25, comprising rotating the bolt to lock
the bolt into the channel of the rail.
27. The method of claim 25, comprising inserting one or more tabs
of the clamp adjacent the photovoltaic module to mitigate rotation
of the clamp relative to the photovoltaic module.
28. The method of claim 27, the bolt comprising a shaft having a
non-cylindrical portion, and the clamp having a corresponding
non-cylindrical aperture through which the non-cylindrical portion
of the shaft is inserted, and inserting one or more tabs of the
clamp adjacent the photovoltaic module comprising inserting one or
more tabs of the clamp adjacent the photovoltaic module to mitigate
rotation of the bolt relative to the rail while the spacer is being
compressed.
Description
BACKGROUND
[0001] The present application relates to, among other things,
systems and/or methods for clamping photovoltaic (PV) modules to a
rail and/or rail system configured to support the photovoltaic
modules (e.g., to form a PV array).
[0002] Solar power often refers to the conversion of energy from
sunlight to electricity (e.g., to power an appliance, car, home,
business, etc.). Solar power generation has become increasingly
popular given a shift away from producing electricity via fossil
fuels (e.g., coal, oil, natural gas, etc.). Such an increase in
popularity may be attributed to numerous factors. For example, the
production of electricity via sunlight is considered to be more
environmentally friendly than using fossil fuels (e.g., few to no
pollutants are emitted using solar technology). Moreover, the
conversion efficiency (e.g., amount of sunlight converted into
electricity) has continued to increase while the cost to
manufacture photovoltaic modules (e.g., solar panels) has
decreased, allowing for more widespread applicability (e.g., both
in terms of geographic location and affordability).
[0003] To convert sunlight or other light into electricity, one or
more photovoltaic modules, comprised of a plurality of photovoltaic
cells, may be used. Respective photovoltaic cells are configured to
convert light energy (e.g., from the sun) into electricity via the
photovoltaic effect (e.g., where a voltage and/or electric current
is created in a material based upon exposure to light). Because the
power that one module can produce is usually insufficient to meet a
desired power output (e.g., to power a home and/or business), a
plurality of photovoltaic modules may be operably coupled together
and arranged to form a photovoltaic array. Traditionally, the
photovoltaic modules have been arranged in a grid of rows or
columns. However, in some applications, they may be arranged in a
different pattern.
[0004] To secure the photovoltaic modules, a traditional rail and
top-down clamping apparatus have been employed. The rails often
comprise a channel and the clamping apparatus comprises a t-shaped
bolt (e.g., also referred to as a "t-bolt") that is designed to fit
into the channel of the rail. In operation, the t-bolt is usually
inserted into the channel and turned to a desired orientation
relative the channel. A clamp of the clamping apparatus is then
attached to the t-bolt and secured via a nut to mitigate movement
of the module relative to the rail.
[0005] Typically, components of the clamping apparatus (e.g., the
t-bolt, clamp, and nut) are shipped individually to the
installation site and assembled once the modules have been set in
place. That is, the module is set in place, the t-bolt is inserted
into the channel, the clamp is attached to the bolt, the nut is
attached to the bolt, and then the nut is tightened to secure the
module (e.g., via the clamp). Given that a typical photovoltaic
array comprises at least 12 modules, and may exceed 100 modules,
and given that a plurality of clamping apparatuses may be used to
secure respective modules, the installation process may be labor
intensive (e.g., adding to the total cost of the photovoltaic
array). Moreover, given that clamping apparatuses are assembled on
site, bolts, clamps and/or nuts may be lost, dropped, etc. during
the installation process, further increasing installation time
and/or cost.
SUMMARY
[0006] This Summary is provided to introduce a selection of
concepts in a simplified form that are further described below in
the Detailed Description. This Summary is not intended to identify
key factors or essential features of the claimed subject matter,
nor is it intended to be used to limit the scope of the claimed
subject matter.
[0007] Among other things, a clamping apparatus is provided that is
configured to address and/or mitigate at least some of the
aforementioned issues. The clamping apparatus comprises a spacer
(e.g., comprised of a compressible material) that is inserted
between a head of a bolt (e.g., the t-shaped portion of a t-bolt)
and a clamp for securing a photovoltaic module. The spacer is
configured to cause a space of a specified length to be created
between the head of the bolt and the clamp. Generally, this space
is sufficient to accommodate a photovoltaic (PV) module (e.g., PV
module can be slide between the head of the bolt (e.g., or a rail
into which a head of the bolt is inserted) and the clamp). A nut of
the clamping apparatus can then be tightened to secure the
photovoltaic module (e.g., causing the spacer to be compressed and
the space between the head of the bolt and the clamp to be
reduced). Importantly, the spacer allows the clamping apparatus to
be preassemble and shipped to the job site in a preassembled
configuration and installed in the preassembled configuration, such
that an installer merely has to insert the preassembled
configuration into a rail and tighten the nut to secure a PV module
via the clamp. In this manner, fewer parts may be lost and
installation time and cost may be reduced.
[0008] One or more methods are also provided for attaching a
clamping apparatus to a rail, or a channel within the rail. By way
of example, a method for preassembling a clamping apparatus prior
to insertion of a t-bolt into the channel may be devised (e.g.,
whereas a conventional clamping apparatus has been assembled
piece-by-piece after the t-bolt is inserted into the channel). As
such, the clamping apparatus may be preassembled at the
installation site and/or assembled at a factory and shipped to the
installation site preassembled (e.g., reducing installation cost).
Moreover, in another example method, the clamping apparatus may be
attached to the rail prior to positioning the module relative to
the rail. As an example, installers may insert the clamping
apparatuses into the rails (e.g., prior to installing the rails on
a roof) and/or the rails may be shipped to the installation site
with clamping apparatuses already attached to the rails (e.g.,
further reducing installation cost). It will be appreciated that
such preassembling may occur because the spacer can be configured
to maintain a relative position between a head of a bolt and a
clamp (e.g., secured to the bolt via a nut).
[0009] To the accomplishment of the foregoing and related ends, the
following description and annexed drawings set forth certain
illustrative aspects and implementations. These are indicative of
but a few of the various ways in which one or more aspects may be
employed. Other aspects, advantages, and novel features of the
disclosure will become apparent from the following detailed
description when considered in conjunction with the annexed
drawings.
FIGURES
[0010] The application is illustrated by way of example and not
limitation in the figures of the accompanying drawings, in which
like references generally indicate similar elements and in
which:
[0011] FIG. 1 illustrates an example of a photovoltaic array.
[0012] FIG. 2 illustrates a cross-sectional view of an example
photovoltaic array comprising rails to which one or more
photovoltaic modules can be attached.
[0013] FIG. 3 illustrates an example clamping apparatus.
[0014] FIG. 4 illustrates a top-down view of an example bolt of an
example clamping apparatus.
[0015] FIG. 5 illustrates a top-down view of an example clamp of an
example clamping apparatus.
[0016] FIG. 6 illustrates a cross-sectional view of an example
photovoltaic array with a clamping apparatus attached thereto.
[0017] FIG. 7 illustrates a cross-sectional view of an example
photovoltaic array with a clamping apparatus being inserted into a
channel of a rail of the array.
[0018] FIG. 8 illustrates a clamping apparatus being rotated to
lock the clamping apparatus into a channel of a rail of a
photovoltaic array.
[0019] FIG. 9 illustrates an example flow diagram of an example
method for preassembling a rail of a photovoltaic array.
[0020] FIG. 10 illustrates an example flow diagram of an example
method for securing a photovoltaic module to a rail.
DESCRIPTION
[0021] The claimed subject matter is now described with reference
to the drawings, wherein like reference numerals are generally used
to refer to like elements throughout. In the following description,
for purposes of explanation, numerous specific details are set
forth in order to provide a thorough understanding of the claimed
subject matter. It may be evident, however, that the claimed
subject matter may be practiced without these specific details. In
other instances, structures and devices are illustrated in block
diagram form in order to facilitate describing subject matter.
[0022] FIG. 1 illustrates an example photovoltaic array 100 (e.g.,
also referred to as a solar panel array, solar array, and/or the
like) comprised of a plurality of photovoltaic modules 102 that are
arranged along and/or attached to one or more rails 104 (e.g.,
substantially occluded by the overlying modules 102). As
illustrated herein, the rails 104 extend substantially parallel to
the a-axis, although they may extend substantially parallel to the
b-axis. Moreover, as will be described in further detail with
respect to FIG. 2, respective rails further comprise a channel that
runs along the length of the rails (e.g., in the example
embodiment, channels run parallel to the a-axis).
[0023] Channels in the rails may be useful for securing the modules
102 to the rails 104 via one or more clamping apparatuses 106, 108.
For example, in the illustrated embodiment, the modules 102 are
secured to the rails 104 via end-clamp apparatuses 106 and
mid-clamp apparatuses 108. Generally, the differences between
end-clamp apparatuses 106 and mid-clamp apparatuses 108 are merely
based upon the number of modules the clamping apparatus is intended
to secure and/or the location of the clamping apparatus. For
example, in the illustrated embodiment, end-clamp apparatuses 106
are positioned on an edge of the array 100 and are respectively
configured to secure merely one module 102. Mid-clamp apparatuses
108 are positioned between modules 102 of the array 100 and are
configured to secure two or more modules 102, for example. As used
herein, the terms clamping apparatus, clamping apparatuses, and/or
the like are intended to be interpreted in a broad sense to
comprise both end-clamp apparatuses 106 and mid-clamp apparatuses
108.
[0024] While a specific rail type and/or structure configuration is
shown in the examples described herein, it is to be understood that
the clamping apparatus(es) described herein can be employed with
alternative rail and/or attachments systems to the extent
practical. Moreover, the number of modules comprised in the example
array 100, the arrangement of the array 100, and/or the arrangement
of the modules 102 relative to the rails 104 are not intended to
limit the scope of the appended claims. Further, while specific
reference is made to the applicability of the clamping apparatus
for securing photovoltaic modules, it will be appreciated that the
clamping apparatus(es) may find utility in other applications.
Thus, to the extent practical, the instant disclosure, including
the scope of the claims, is not intended to be limited to a
clamping apparatus for securing photovoltaic modules.
[0025] FIG. 2 illustrates a cross-sectional view of a photovoltaic
array (e.g., 100 in FIG. 1) (e.g., taken along line 2-2 in FIG. 1).
As illustrated, a photovoltaic module 202 (e.g., 102 in FIG. 1) is
situated on top of one or more rails 204 (e.g., 104 in FIG. 1). The
rails 204 are configured to accommodate a clamping apparatus (not
shown) to secure the module 202 to the rail 204. For example, in
the illustrated embodiment, respective rails 204 comprise a channel
206 through which a portion of the clamping apparatus (e.g., a
t-shaped or other-shaped head of the clamping apparatus (e.g., or,
more particularly, of a bolt portion of the clamping apparatus))
may be inserted. However, other mechanisms for securing the
clamping apparatus to the rail are also contemplated. For example,
in another embodiment, the rail comprises an extruded portion to
which the clamping apparatus attaches.
[0026] It will be appreciated that one or more of the rails 204 may
further comprise other channels 208, 210 that may be utilized to
secure the rail to other rails and/or to secure the rail to a
supporting structure (e.g., such as a roof or pole to which the
photovoltaic array is attached), for example. Moreover, the shape
of the rail, number and/or size of additional channels, etc. may
depend upon, among other things, how the rails 204 are coupled
together (e.g., if they are coupled together), a weight of the
modules 202, a structure to which the rails 204 attach, etc.
[0027] FIG. 3 illustrates an exploded view of a clamping apparatus
300 (e.g., 106, 108 in FIG. 1) that may be configured to secure one
or more photovoltaic modules (e.g., 202 in FIG. 2) to a rail(s)
(e.g., 204 in FIG. 2). It will be appreciated that FIG. 3
illustrates what is referred to above as a mid-clamp apparatus
(e.g., based upon the size and/or shape of the clamp 308), although
the features described herein may also be applicable to end-clamp
apparatuses.
[0028] The clamping apparatus 300 comprises a threaded bolt 302, a
grounding clip 304, a spacer 306, a clamp 308, and a nut 310. It
will be appreciated that at least some of these components may be
optional and/or the clamping apparatus 300 may comprise additional
components not described herein. For example, in one embodiment,
the grounding clip 304 (e.g., washer) may be optional.
[0029] The threaded bolt 302 may comprise at least two ends (e.g.,
a first end and a second end), where one end may be defined by a
head 312 that is configured to be inserted into a channel of a
rail, for example. Typically, the head 312 has at least one
dimension that is greater than a width of the channel, which
reduces the possibility of the bolt 302 coming out of the channel
once the head 312 is inserted into the channel and/or oriented as
desired relative to the channel. By way of example, in the
illustrated clamping apparatus 300, the bolt 302 comprises a
T-shaped portion or T-shaped head 312. As will be further
understood in view of FIGS. 7-8, such a bolt 302 is configured to
(easily) slip into the channel of the rail when it is oriented in a
first manner relative to the channel (e.g., when the more narrow
dimension of the head 312 is perpendicular to the length of the
channel) and to be secured in the channel when it is oriented in a
second manner relative to the channel (e.g., when the more narrow
dimension of the head 312 is parallel to the length of the
channel).
[0030] Alternatively, in another embodiment, the threaded bolt 302
may not comprise a defined head 312. Rather, a nut and/or other
component may be coupled to the bolt 302 to substantially form a
head that has at least one dimension that is greater than a width
of the channel, for example.
[0031] The example clamping apparatus 300 also comprises a
grounding clip 304. The grounding clip may be selectively coupled
to a shaft of the bolt 302 and/or may be permanently affixed the
bolt 302. For example, in one embodiment, the grounding clip 304
may comprise a washer with smooth and/or jagged surfaces. By way of
example, the washer may comprises one or more teeth that are
configured to mitigate rotation of the washer relative to the rail
and/or are configured to pierce into the rail (e.g., comprised of
an anodized aluminum) to provide a gas tight connection between the
washer and the rail, for example (e.g., mitigating oxidation). It
will be appreciated that by coupling the rail to the grounding clip
304 as described, the clamping apparatus 300 and/or the
photovoltaic module to which it is affixed may be ground to the
rail. In this way, a ground wire may not be run to respective
clamping apparatuses and/or to respective photovoltaic modules, for
example.
[0032] In another embodiment, the grounding clip 304 may be
configured to attach to a ground wire that is coupled to ground
wires from other clamping apparatuses and/or coupled to an earthing
electrode (e.g., metal rod), for example. Such a feature may reduce
undesired contact with a voltage should electrical components of
the array fail, reduce build-up of electricity, and/or provide a
channel for conducting high currents associated with lightning
strikes, for example.
[0033] It will be appreciated that the illustrated grounding clip
304 (e.g., which has a shape similar to a washer) is merely one of
numerous examples of grounding clips that may be utilized. In
another embodiment, the grounding clip 304 is simply a ground wire
that is wrapped around, soldered, and/or otherwise attached to a
portion of the clamping apparatus 300, for example.
[0034] In yet another embodiment, the grounding clip 304 may not
serve to necessarily ground the clamping apparatus 300, but rather
to add support to the clamping apparatus 300 and/or a portion
thereof. For example, as will be evident from FIG. 6, the grounding
clip 304 (e.g., which may be a metal washer) may reside between the
rail and the spacer 306 (e.g., which may be comprised of a
compressible material) and may be configured to support the spacer
306 against the rail (e.g., such that the weight of the spacer 306,
clamp 308, and/or nut 310 is dispersed across the (rigid) grounding
clip as opposed to the (compressible) spacer (e.g., which could
potentially collapse into the channel of the rail)). Thus, in some
embodiments, the grounding clip 304 may not necessarily be
configured to (e.g., limited to) electrically ground the clamping
apparatus 300, for example.
[0035] Still, in some other embodiments, the grounding clip 304 may
be optional. For example, in some embodiments, the spacer 306 may
be sufficiently sized to support weight of the spacer 306, clamp
308, and/or nut 310 across the channel and/or may be comprised of a
material that is rigid enough to support the weight without
collapsing into the channel. Moreover, in other embodiments, the
spacer 306 may fit into the channel and remain in contact with the
head of the bolt 302 once the clamping apparatus 300 is inserted
into the channel (e.g., such that support of weight by spacer 306
is less important).
[0036] The clamping apparatus 300 further comprises the spacer 306
configured to be selectively coupled to the shaft of the bolt 302
and/or permanently affixed to the bolt 302. It will be appreciated
that while the spacer is generally illustrated as having a
concentric arrangement relative to the bolt 302, the instant
disclosure, included the scope of the appended claims, is not
intended to be so limited. That is, unless specified to the
contrary, any configuration(s), design(s), etc. are contemplated
for the spacer (e.g., that facilitate the functions provided
herein). The spacer 306 is also configured to position the clamp
308 of the clamping apparatus 300 a specified distance from the
first end (e.g., head 312) of the bolt 302 and/or to position the
clamp 308 a specified distance from (e.g., a top edge of) the rail
once the clamping apparatus 300 is attached to the rail, for
example.
[0037] The spacer 306 is typically comprised of a compressible
material and is configured to be compressed once the photovoltaic
module is positioned appropriately relative to the rail to secure
the module. That is, once the module is in the desired position, an
installer, for example, may tighten the nut 310, causing the spacer
306 to be compressed and reducing the space between the rail and
the clamp 308. Such compressible materials may comprise, but are
not limited to, a spring (e.g., such as a rubber spring or metal
spring), a polystyrene, and/or a compressible metal structure
(e.g., such as a soft metal).
[0038] The clamping apparatus 300 also comprises a clamp 308
configured to be selectively coupled to the shaft of the bolt 302
and/or permanently affixed to the bolt 302. The clamp 308 is also
configured to secure one or more photovoltaic modules to the rail.
For example, the clamp 308 may comprise one or more edges that are
configured to extend over a portion of the module(s). When the nut
310 is selectively coupled to the shaft via the second end of the
bolt and tightened, the one or more edges extending over the
portion of the module may apply pressure to the module, causing the
module to be secured to the rail. In this way, the nut 310 acts to
secure the clamp 308 and the spacer 306 to the bolt 302 and/or to
apply pressure to the clamp 308 and/or the spacer 306 when
tightened, for example.
[0039] The clamping apparatus 300 may also comprise other features
that promote safely securing the one or more modules to the rail,
for example. By way of example, in one embodiment, the clamp 308
comprises one or more tabs 314 that are configured to contact a
side-edge of one or more modules (e.g., as opposed to a top edge
facing the sunlight) and/or to be partially inserted between two or
more modules. Such tabs 314 are configured to reduce and/or
mitigate rotation of the clamp relative to the module while the nut
310 is being tightened, for example.
[0040] Moreover, as illustrated in FIGS. 4-5 (e.g., illustrating
top-down views of the bolt 302 and the clamp 308, respectively) the
shaft of the bolt 302 may comprise a non-cylindrical portion (e.g.,
such as a flat/shaved edge) and the clamp 308 may comprise a
non-cylindrical aperture 316 (e.g., of a similar shape to the
non-cylindrical portion of the shaft) into which the
non-cylindrical portion of the shaft is inserted. Such
non-cylindrical features of the bolt 302 and the clamp 308 and/or
the tabs 314 of the clamp may mitigate rotation of the bolt 302,
and the clamping apparatus 300 generally, relative to the rail once
the bolt is inserted into the channel and turned appropriately
(e.g., mitigating rotation of the bolt 302 as the nut 310 is being
tightened). That is, stated differently, the one or more tabs 314,
the non-cylindrically shaped aperture 316, and the
non-cylindrically shaped portion of the bolt 302 may facilitate
alignment of the first end of the bolt 302 (e.g., the head 312)
within a channel of the rail, such that rotation of the bolt 302
relative to the channel is mitigated as the one or more modules are
being secured (e.g., as the nut 310 is being tightened).
[0041] It will be appreciated that these and other features may be
described in more detail in U.S. Patent Publication 2011/0299957
and assigned to Preformed Line Products Company, at least some of
which may be incorporated herein by reference. For example, another
feature of the bolt 302 may be that one or more edges of the head
312 of the bolt 302 are rounded while other edges are substantially
square to control how the bolt 302 can be rotated within the
channel of the rail. For example, in one embodiment, the head 312
comprises one round corner and three square corners such that the
bolt can be rotated in merely one direction relative to the rail
when the t-shaped head of the bolt is inserted into a channel of
the rail (e.g., because the square corners limit rotation in other
directions). Moreover, once turned to a specified position (e.g.,
turned 90 degrees relative to an initial position when the
bolt/clamping apparatus is inserted into the channel (e.g., such
that the head is substantially perpendicular to the channel as
described further in FIGS. 7-8), the head 312 with merely one round
corner may mitigate further rotation of the bolt 302 (e.g., to
mitigate rotating the bolt further such that the head 312 becomes
parallel with the channel).
[0042] FIG. 6 illustrates a cross-sectional view (e.g., taken along
line 6-6 in FIG. 1) illustrating a clamping apparatus 600 (e.g.,
300 in FIG. 3) securing a photovoltaic module 602 (e.g., 102 in
FIG. 1) to a rail 604 (e.g., 104 in FIG. 1) via a channel 606
(e.g., 206 in FIG. 2). The clamping apparatus 600 comprises a bolt
608 (e.g., 302 in FIG. 3) comprising a head 610 (e.g., 312 in FIG.
3) that is inserted into the channel 606 of the rail 604. The
example clamping apparatus 600 also comprises a grounding clip 612
(e.g., 304 in FIG. 3), spacer 614 (e.g., 306 in FIG. 3), clamp 616
(e.g., 308 in FIG. 3) (e.g., including tabs 620 (e.g., 314 in FIG.
3) that abut the side of the module 602), and a nut 618 (e.g., 310
in FIG. 3).
[0043] FIG. 7-8 illustrate how a preassembled clamping apparatus
700 (e.g., 600 in FIG. 6) comprising a bolt 702 (e.g., 302 in FIG.
3) having a t-shaped head 704 (e.g., 312 in FIG. 3) may be
selectively coupled to a rail 706 (e.g., 204 in FIG. 2). More
particularly, FIG. 7 illustrates a portion of the clamping
apparatus 700 being inserted into a channel 708 (e.g., 206 in FIG.
2) of the rail 706. The t-shaped head 704 is turned such that a
more narrow dimension 710 of the head 704 is perpendicular the
length of the channel 708 (e.g., going into and out of the page),
allowing the t-shaped head 704 to be lowered into the channel
708.
[0044] Once the t-shaped head 704 is positioned in the channel 708,
the bolt 702 (e.g., and/or the entire clamping apparatus 700) may
be rotated 712 clockwise and/or counter-clockwise (e.g., 90
degrees) until the narrow dimension of the head 704 is parallel or
substantially parallel to the length of the channel 708 (e.g., such
that the narrow dimension of the head 704 is going into and/or out
of the page) as illustrated in FIG. 8. It will be appreciated that
this changed orientation of the head 704 relative to the channel
708 can reduce (e.g., mitigate) the possibility of the clamping
apparatus 700 becoming unsecured from the rail 706.
[0045] FIG. 9 illustrates an example method 900 which may be
utilized to preassemble a rail (e.g., to which a photovoltaic
module attaches) for shipment to an installation site, for example.
The example method 900 begins at 902, and a rail configured to
secure one or more photovoltaic modules is preassembled at 904.
Preassembling the rail typical comprises, among other things,
coupling a clamping apparatus to the rail at 906. The clamping
apparatus is generally configured similar to the clamping apparatus
illustrated in FIG. 3 and comprises, among other things a bolt, a
clamp, and a spacer. As previously described, the spacer is
configured to position the clamp a specified distance from the head
of the bolt and/or a specified distance from an edge of the rail
into which a portion of the bolt is inserted.
[0046] The clamping apparatus may be assembled prior to coupling it
to the rail and/or it may be assembled as part of the act of
coupling the clamping apparatus to the rail. For example, in one
embodiment, the clamping apparatus is preassembled such that the
bolt, spacer, and clamp are coupled together (e.g., fastened
together) prior to the clamping apparatus being coupled to the rail
(e.g., in a factory and/or at an installation site). In this way,
the clamping apparatus is one unit prior to assembly with the rail.
However, in another embodiment, coupling the clamping apparatus to
the rail may comprise assembling the clamping apparatus on the
rail. For example, a first end of the bolt may be inserted into a
channel of the rail, and the rail may be positioned/oriented as
desired. Subsequently, the spacer may be associated with the bolt
(e.g., via an aperture of the spacer (e.g., such that the spacer is
positioned between the rail and a second end of the bolt)), a clamp
may be placed onto the bolt via an aperture of the clamp, and a nut
may be secured to the bolt to hold the spacer and clamp in
place.
[0047] Typically, the spacer is configured to maintain a relative
orientation of the clamping apparatus and the rail (e.g., such that
angle between the clamping apparatus and a top edge of the rail is
substantially ninety degrees). Moreover, in one embodiment, the
spacer may be slightly compressed as part of the preassembly such
that a degree of pressure is applied to the rail. Such pressure may
further assist in maintaining a position of the clamping apparatus
relative to the rail (e.g., such that the clamping apparatus does
not slide along the channel). Thus, the spacer may be utilized to
reduce slippage of the clamping apparatus when (an edge of) a
module is positioned between the rail and the clamp of the clamping
apparatus, for example.
[0048] As described above, in some embodiments, the clamp and/or
the bolt may comprise features that further aid in the installation
of the photovoltaic modules and/or in securing the photovoltaic
module(s) to the rail. For example, in one embodiment, the bolt may
comprise a shaft having a non-cylindrical portion and the clamp may
comprise a corresponding (e.g., similarly shaped), non-cylindrical
aperture through which the non-cylindrical portion of the bolt can
be inserted. In this way, rotation of the bolt relative to the
clamp is reduced (e.g., to reduce the possibility of the bolt being
turned in such a manner that it can slip and/or rotate out of the
channel). Moreover, the clamp may comprise tabs that abut a
side-edge of the photovoltaic modules to further reduce the
possibility of the clamp rotating.
[0049] Once the rail is preassembled at 904 (e.g., which includes
coupling the clamping apparatus to the rail at 906), the
preassembled rail may be shipped for assembly at 908. In this way,
the rail may be shipped from the factory with the clamping
apparatuses preinstalled at specified locations to reduce
installation time on site, for example. To complete the
installation onsite, the installer therefore merely attaches the
rails to an installation site (e.g., a roof) inserts one or more
modules into the space between the top edge of the rail and the
clamp (e.g., as established by the spacer), secures the module by
tightening a nut of the respective clamping apparatuses (e.g.,
already installed on the rail), and connects wiring of photovoltaic
module(s) to a power grid and/or power consumption device, for
example.
[0050] The example method 900 ends at 910.
[0051] FIG. 10 illustrates a method 1000 for securing a
photovoltaic module to a rail when the rail is not preassembled as
provided for in the example method 900 of FIG. 9. By way of
example, FIG. 10 provides for a method 1000 where the clamping
apparatus is attached to the rail at the installation site (e.g.,
as opposed to being attached to the rail at factory prior to
shipment of the rails).
[0052] The example method 1000 begins at 1002, and a photovoltaic
module is placed proximate the rail at 1004. Generally, a diagram
provided by the photovoltaic array manufacturer describes how the
photovoltaic modules are to be arranged and an installer, for
example, may place the modules on the rails accordingly.
[0053] At 1006 in the example method 1000, one end of a
preassembled clamping apparatus is inserted into a channel of the
rail (e.g., before or after a photovoltaic module is placed
proximate the rail). For example, as described above, the clamping
apparatus may comprise a bolt having a t-shaped head that can be
inserted into the channel and rotated (e.g., about 90 degrees) to
lock or secure the clamping apparatus to the rail. Alternatively,
in another embodiment, a portion of the clamping apparatus may be
feed through an outer (e.g., `open`) edge of the channel and moved
along the channel until it is located in a desired position.
[0054] As described with respect to FIG. 3, generally the clamping
apparatus comprises, among other things, a bolt, a clamp, and a
spacer. The spacer is configured to position the clamp a specified
distance from a top edge of the rail and/or from a head of the
bolt, for example. In this way, the module may be seated between
the rail and the clamp with minimal (if any) adjusts to the
clamping apparatus (e.g., besides tightening the nut to secure the
module).
[0055] Preassembling of the clamping apparatus may occur at a
factory and/or may occur at the installation site, for example. As
an example, in one embodiment, the clamping apparatuses may be
preassembled at the factory and shipped, preassembled, to the
installation site, where the installers can attach them to the
rails. In another embodiment, an installer may assemble the
clamping apparatuses at the installation site, prior to the
clamping apparatuses being coupled to the rail, for example.
[0056] It will be appreciated that while the example method 1000
illustrates the placement of the photovoltaic modules proximate the
rail prior to the insertion of the preassembled clamping apparatus
into a channel of the rail, such actions may be reversed. For
example, given a diagram describing the arrangement of the modules
(e.g., and clamping apparatuses), the installer may begin by
attaching the clamping apparatuses to the rail and may proceed to
place or slide the photovoltaic modules into place once the
clamping apparatus(es) are attached/affixed to the rail.
[0057] At 1008, the spacer of the clamping apparatus is compressed
to reduce the distance between the clamp and the top edge of the
rail and/or the distance between the clamp and the head of the
bolt. By way of example, a nut or other fastener of the clamping
apparatus may be tightened to apply pressure to the spacer, causing
it to compress. The applied pressure also typically causes the
clamp to apply pressure on the module, causing the module to be
secured to the rail by way of the clamping apparatus.
[0058] At 1010, the example method 1000 ends.
[0059] It may be appreciated that the words "example" and/or
"exemplary" are used herein to mean serving as an example,
instance, or illustration. Any aspect, design, etc. described
herein as "example" and/or "exemplary" is not necessarily to be
construed as advantageous over other aspects, designs, etc. Rather,
use of these terms is intended to present concepts in a concrete
fashion. As used in this application, the term "or" is intended to
mean an inclusive "or" rather than an exclusive "or". That is,
unless specified otherwise, or clear from context, "X employs A or
B" is intended to mean any of the natural inclusive permutations.
That is, if X employs A; X employs B; or X employs both A and B,
then "X employs A or B" is satisfied under any of the foregoing
instances. In addition, the articles "a" and "an" as used in this
application and the appended claims may generally be construed to
mean "one or more" unless specified otherwise or clear from context
to be directed to a singular form. Also, at least one of A and B or
the like generally means A or B or both A and B.
[0060] Although the disclosure has been shown and described with
respect to one or more implementations, equivalent alterations and
modifications will occur to others skilled in the art based upon a
reading and understanding of this specification and the annexed
drawings. The disclosure includes all such modifications and
alterations and is limited only by the scope of the following
claims. In particular regard to the various functions performed by
the above described components (e.g., elements, resources, etc.),
the terms used to describe such components are intended to
correspond, unless otherwise indicated, to any component which
performs the specified function of the described component (e.g.,
that is functionally equivalent), even though not structurally
equivalent to the disclosed structure which performs the function
in the herein illustrated example implementations of the
disclosure. Similarly, illustrated ordering(s) of acts is not meant
to be limiting, such that different orderings comprising the same
of different (e.g., numbers) of acts are intended to fall within
the scope of the instant disclosure. In addition, while a
particular feature of the disclosure may have been disclosed with
respect to only one of several implementations, such feature may be
combined with one or more other features of the other
implementations as may be desired and advantageous for any given or
particular application. Furthermore, to the extent that the terms
"includes", "having", "has", "with", or variants thereof are used
in either the detailed description or the claims, such terms are
intended to be inclusive in a manner similar to the term
"comprising."
* * * * *